IC2 Webinar: Evaluating Product Performance during ... Product...Dec 01, 2016 · • Alternative...
Transcript of IC2 Webinar: Evaluating Product Performance during ... Product...Dec 01, 2016 · • Alternative...
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IC2 Webinar: Evaluating Product Performance during Alternatives AssessmentDecember 1, 2016
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Alex Stone, Sc. D.Washington State Department
of Ecology
1 December 2016
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• PBDE Chemical Action Plan issued in 2006• Ban legislation passed and signed into law in 2007
– Banned the use of Penta- and Octa-BDE mixtures– Prohibited sale of mattresses containing Deca– Ban possible on Deca contained in electronic enclosures and
residential upholstered furniture• IF Fire Safety Maintained• IF safer and technically feasible alternative(s) identified
WA Legislation
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• Ecology conducted an alternatives assessment for Deca in these applications
• Alternative Assessment report completed Jan. 2009• Ban on use of Deca in electronic enclosures and
residential furniture became effective in Jan. 2011• Ecology tests products to guarantee compliance
WA Legislation
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Deca Alternatives Built upon work done in PBDE Chemical Action
Plan & subsequent work around the world
Evaluated Deca Assessments What products/plastics included What criteria used to evaluate alternatives What alternatives evaluated Conclusions Strengths/weaknesses
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‘Safer’ Considerations used in Deca Assessment
1. Market and Technical Analysis Do alternatives exist? Do they meet the same need?
2. Toxicity Evaluation If toxicity worse or equivalent, no further consideration Used Clean Production Action’s Green Screen™
3. Exposure Evaluation Are there substantive differences in exposure? Are the same amounts used? Are the physicochemical properties substantively
different?
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‘Safer’ Considerations (cont.)
4. Performance Can an alternative be used without changing process? Can process be changed to use alternative? Are there other viable alternatives (redesign product so
chemical is not needed, etc.)? Can fire safety be maintained? Is more or less of the alternative needed?
5. Availability Are alternatives currently being sold for intended application? Are alternatives currently being used in similar products?
6. Cost Is more or less of the alternative needed? What impact does switch have upon cost of final product? Is it cost prohibitive?
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Performance of Alternatives
Three possible alternatives evaluated
1. Use a different flame retardant
2. Change plastic and flame retardant
3. Redesign product to eliminate need for flame retardant
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Performance: Use different FR High Impact Polystyrene (HIPS) used most
often in electronic enclosures Deca and other brominated flame retardants
used in HIPS Non-brominated flame retardants cannot be
used in place of Deca in HIPS
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Performance: Change Plastic and FR Deca alternatives can be used in other
plastic blends
– HIPS/PPE (polyphenylene ether)
– PC (polycarbonate)/ABS (acrylonitrile butadiene styrene)
Fire safety maintained
Flame retardant manufacturers confirm
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Performance: Redesign product to eliminate FR
Options are being explored: Some success in Europe separating power supply from
display thereby decreasing need for flame retardants in enclosures
Evaluating options for more inherently flame resistant plastics and/or using other, non-plastic enclosures
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Performance: Fire StandardsTwo Questions:
1. How does a TV or computer manufacturer prove that his product meets the fire standard?
2. How does Ecology and Health know that Deca alternatives meet this standard?
Information Evaluated National Fire Standards Lowell Institute Report Danish EPA Report Karlsruhe Report
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Performance: Karlsruhe ReportEvaluated alternatives to Deca using various
criteria: Processability Thermal stability Mechanical Properties Hydrolytic stability Recyclability RoHS and WEE directives
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Performance: Karlsruhe Report (cont.)
Evaluated PC/ABS and HIPS/PPOTested plastics to evaluate fire safety rating
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Enclosures Performance Conclusions1. Changing to HIPS blends allow use of
alternatives2. Alternatives used in same amounts and ways3. Performance requirements met by alternatives4. Fire safety protected5. Industry is already moving in this direction
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Furniture Performance Conclusions1. Furniture can be made without FRs2. Barrier fabrics and other techniques provide
fire safety3. Preferred alternative is to produce furniture
without FRs
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More Information
Alternatives to Deca-BDE in Televisions and Computers and Residential Upholstered Furniture
(https://fortress.wa.gov/ecy/publications/publications/0907041.pdf)
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Contact Information
Alex StoneWA State Department of EcologySafer Chemical Alternative Chemist(360) [email protected]
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© Toxics Use Reduction Institute University of Massachusetts Lowell© Toxics Use Reduction Institute University of Massachusetts Lowell
Product Performance and Alternatives Assessments
TURI Cleaning Lab
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21© Toxics Use Reduction Institute University of Massachusetts Lowell
TURI Cleaning Lab
• Providing technical assistance since 1993• SSL has helped hundreds of companies find safer
alternatives to hazardous cleaning solvents
• The implementation rate for clients of the lab is many times higher than the national average (10%) for technical assistant providers
• From 1993-2007 -Over one-third of the companies fully adopt the lab’s recommendations
• From 2008 – More than three-quarters adoption rate
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22© Toxics Use Reduction Institute University of Massachusetts Lowell
Want to Know How? Of Course You Do• Process is challenging
– Thousands of products– Different information from different vendors– What is right for some may not work for others
• Need for an easier selection method– Independent analysis of products– Objective operating conditions– Process specific final evaluations
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23© Toxics Use Reduction Institute University of Massachusetts Lowell
How Have We Done It?
• Safety Screening– CleanerSolutions
• Performance Testing– Customized evaluations
• EHS Assessment– P2OASys
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24© Toxics Use Reduction Institute University of Massachusetts Lowell
Questions to Ask
• What is the purpose of cleaning• What are the problems with present
cleaning system• What are you trying to remove (soils)• What is being cleaned (substrates)• How are you cleaning it (equipment)• How do you determine how clean is clean
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25© Toxics Use Reduction Institute University of Massachusetts Lowell
Review Current System
• Contacted by company with cleaning related issue
• Gather background information on process– Cleaning Lab Test Request form
• Material of parts to be cleaned• Contaminants• Current Solvent or other alternatives tested• Available Equipment• Operating conditions (time, temp, conc.)
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26© Toxics Use Reduction Institute University of Massachusetts Lowell
Review Current System
• Site visit– Complete Test Request form– Gather samples and MSDS
• Contaminants• Current Solvent• Dirty Parts
– Identify possible adjustments to process
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27© Toxics Use Reduction Institute University of Massachusetts Lowell© Toxics Use Reduction Institute University of Massachusetts Lowell
Keys to Success
V. Pilot Plant / Scale-up Feasibility TrialsObtain input from employees that will be working on new process•Identify areas concerns•Arrange for lab loaning of equipment for further on-site testing•Follow up lab work based on client feedback
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28© Toxics Use Reduction Institute University of Massachusetts Lowell
Testing an Alternative Phase 1
• TURI Lab Database– Used to identify safer and effective products
• Safety Screening Scores– VOC, ODP, GWP, HMIS/NFPA, pH
• Matching Performance– Contaminant, substrate, equipment, current solvent
www.cleanersolutions.org
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29© Toxics Use Reduction Institute University of Massachusetts Lowell
Testing an Alternative Phase 2
• Initial laboratory evaluation of alternatives– Using basic operating conditions
• Minimal concentration • Short times• Little agitation
– Using coupons matching part substrate– Using supplied contaminants– Compare with current solvent (if possible)
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30© Toxics Use Reduction Institute University of Massachusetts Lowell
Testing an AlternativePhase 3• Advanced lab evaluation
– Using client specific operating conditions• Moderate concentration (if necessary)• Times• Appropriate agitation (match current equipment)
– Using coupons matching part substrate– Using supplied contaminants– Compare with current solvent (if possible)– Determine if there are any health risks that the
screening does not address• TURI’s Pollution Prevention Options Analysis System -
P2OAYSys
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31© Toxics Use Reduction Institute University of Massachusetts Lowell
Testing an AlternativePhase 4• Pilot cleaning in lab setting
– Using client specific operating conditions– Using client supplied parts– Compare with current solvent (if possible)– Send/bring parts to client for assessment
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32© Toxics Use Reduction Institute University of Massachusetts Lowell
Testing an AlternativePhase 5• Pilot testing at facility
– Using best alternative cleaning products– Using operating conditions from lab piloting
• Modify conditions if necessary– Set up piloting off-line from current system
• Compare pilot cleaned parts with current system for parts from the same manufacturing lot
• Get end user input for performance
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33© Toxics Use Reduction Institute University of Massachusetts Lowell
Third Party Certifications
• Green Seal• EPA Safer Choice• UL - Ecologo
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34© Toxics Use Reduction Institute University of Massachusetts Lowell
Cleaning Standards to Guide Performance Testing
Category Related standards
All purpose – heavy duty GS 8, 37, CCD 110, ASTM D4488 (WK26967 when developed)
All purpose – light duty GS 8, 37, CCD 110
Glass Cleaning GS 8, 37, DCC09 &09A, CCD 110
Bathroom general GS 8, 37, DCC16 I & II, CCD 110, ASTM D5343
Bathroom toilet bowl cleaning (hard water removal)
GS 37, DCC16 I & II, CCD 110, Marble block test
Grease removal from hard surfaces DCC17
Automatic Dishwashing DCC05A; ASTM D3556
Hand Dishwashing DCC-10, ASTM D4009
Oven Cleaners DCC12
Flooring and Washable Walls ASTM D4488; ASTM D5343
Hand Washing GS41
Odor Elimination ASTM E1593
Floor stripping GS 40 - ASTM D 1792-82, ASTM D 3206-92, ASTM D 3207-9
Oil cleaning – heavy (motor) ASTM G122
Oil cleaning – light (cooking) ASTM G122
Whiteboard cleaning
Stainless Steel cleaning/polishing
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35© Toxics Use Reduction Institute University of Massachusetts Lowell
Alternative Performance Requirements
• Using another objective, scientifically-validated method conducted under controlled and reproducible laboratory conditions, the product performs as well as or better than a conventional, nationally-recognized product in its category and at equivalent product-specific use directions
• Test methodology and results must be documented in sufficient detail for this determination to be made
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Performance Evaluation for Alternatives Assessment: Collaboration Model
Greg MoroseToxics Use Reduction InstituteUniversity of Massachusetts Lowell
December 1, 2016
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DRAFT
Industry Collaborative Alternatives Assessment Initiatives
Lead Reduction for Electronics IndustryCollaborative performance testing for safer alternatives to lead in electronics.
2001 to 2009http://www.turi.org/Our_Work/Business/Industry_Sectors/Electronics
Hex Chrome Reduction for Aerospace/Defense IndustryCollaborative performance testing for safer alternatives to hex chrome free in aerospace/defense applications.
2012 – ongoinghttp://www.turi.org/Our_Work/Business/Industry_Sectors/Aerospace_Defense
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DRAFT
TURI Collaboration Approach
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1. Use of a toxic chemical(s) of concern is pervasive in an industry sector
2. Toxic chemical is not used for competitive advantage
3. Strong market and/or regulatory drivers to reduce the use of the toxic chemical
4. Significant research required to switch to the use of safer alternatives
5. Time and cost intensive for companies to individually conduct research
6. Independent third party available to manage and coordinate the effort
7. Voluntary participation by government, academic, and industry collaborators
8. Participants provide either in-kind contributions (production equipment, technical expertise, materials, supplies, testing, etc.) or direct funding
9. Intent of participants is to adopt the safer alternative solutions identified
10. All results made public so that other companies can adopt solutions identified
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DRAFT
Lead in Electronics Products
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Toxic Chemical of Concern
Lead
Use Solder, solder paste, board surface finish, component surface finish
Quantity Used (prior to project start)
80 – 90 million pounds used globally on an annual basis
Driver EU Directive: Restriction on the Use of Certain Hazardous Substances (RoHS)
Research Required Technical performance of alternatives for assembly, rework, and long term reliability
Collaborative Research Approach
Formation of the New England Lead-free Electronics Consortium
Alternative Materials Tin, copper, silver, gold
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DRAFT
New England Lead-free Electronics Consortium
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Government Academia
Industry
Pull testingStatistical analysisProject mngmt
FundingOutreach
Technical expertiseFunding, and In-kind contributions
$1.5 million total in direct funding and in-kind contributions
20+ companies in the electronics industry
2001 – 2009 Four Phases of Research
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DRAFT
Hex Chrome in Aerospace/Defense
4141
Toxic Chemical of Concern
Hexavalent chromium
Project Phases 1) Primers/sealants, 2) sealants, 3) structural adhesive coatings
Driver Defense Federal Acquisition Regulation Supplement (DFARS) , May 2011
Research Required Technical performance (corrosion resistance) of alternatives for long term reliability
Collaborative Research Approach
Formation of the Hex Chrome Free Sealant Evaluation Team for Phases 1, 2, and NASA TEERM Project for Phase 3
Alternative Materials zinc phosphate, ammonium phosphite,molybdates
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Hex Chrome Free Sealant Evaluation Team
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Government Academia
Industry
Statistical analysisProject mngmt
Customer requirements
Technical expertiseFunding, and In-kind contributions
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DRAFT
Phase I Test Vehicle
438 stainless steel fasteners (4 with 100 degree countersunk heads, and 4 with socket heads)
Aluminum plates: 2” x 4.5” x 0.25” (alloys 6061 and 7075)
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DRAFT
Phase I - Research Process
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Test plan developmentAll participants
Test vehicle CAD designRaytheon
Stress AnalysisNorthrop Grumman
Aluminum plate machiningUMass Lowell
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DRAFT
Phase I - Research Process
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Conversion Coating (HC)Metalast
Conversion Coating (HCF)Northrop Grumman
Test Vehicle AssemblyRaytheon
Test Vehicle PreconditioningU.S. Navy
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DRAFT
Phase I - Research Process
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Accelerated Corrosion TestLockheed Martin
Long-term Corrosion TestNASA
Statistical Analysis &Write Paper
TURI
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The Training Workgroup continues to plan additional webinars intended to inform and engage. Let us know if you have ideas for future webinar topics or presenters.
Please give us your feedback through the post-webinar survey.
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Thank you for attending.
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